Channel letter and trim cap retaining clip therefor

ABSTRACT

A channel letter has a rear surface for mounting against a raceway, wall, or a structure for supporting the signage, and sheet metal sides defining the figuration of the letter or shape to be depicted. A lighting element is positioned against the rear surface of the enclosure, and a lens is retained to the open front of the enclosure. The lens is secured with a retainer cap and a plurality of retainer clips. Each of the retainer clips comprises as least one side including an outwardly extending leg for retention with the retainer cap.

This application claims the priority benefit, as a continuation-in-partapplication, of U.S. application Ser. No. 13/759,517, filed Feb. 5,2013; which in turn claims the priority benefit of U.S. application Ser.No. 61/619,510, filed Apr. 3, 2012, the disclosures of which areincorporated herein by reference.

FIELD

The present invention relates to channel letters of the type used tocreate signage and, in particular, to an improved retainer clip forretaining the trim cap and lens to the enclosure of a channel letter.

BACKGROUND

Channel letters are used to provide signage for buildings, shoppingmalls, and the like where it is desirable that the signage compriseilluminated letters or any other shapes that are easily seen, even atgreat distances, day or night. Each channel letter consists of anenclosure, usually a metal box, having a rear surface which ispositioned against a raceway, or the wall of a building, on which thesignage is mounted and a plurality of sides which define the figurationof a letter or number (or other shape) which make up a portion of thesign. A light source, such as a neon tube, LEDs, or other lightingmechanisms, can be positioned within the walls of the enclosure andattached to the rear (and/or side) surface to provide illumination forthe letter or shape.

The light sources used in many existing channel letters are neon bulbsrequiring high voltage power with transformers built into the metalenclosures. To prevent injury to those servicing such channels lettersmany municipalities require that such letters be inspected to ensurethat they are adequately sealed using standards set by UnderwritersLaboratories.

It is expected that relatively new technology in lighting sources willsoon become the most prevalent for the manufacturers of channel letters.Specifically, low voltage LED type light sources have been developedwhich provide a very long lasting bright light without requiring thehigh voltage and transformers needed for neon lighting. It is expectedthat channel letters employing the new technology will not be requiredto meet the same standards set by Underwriters Laboratories for neontubes.

In addition to the lighting, a channel letter also includes a planartransparent lens, the outer shape of which corresponds to the figurationof the letter or any other shape defined by the sides of the enclosure.The manufacture of the lens requires that the planar panel oftransparent plastic be cut to the shape of the enclosure. The lens ofexisting channel letters have a trim cap glued or welded to the outeredges thereof which form a border to the lens. The trim cap also has alip which, when assembled to the enclosure, is shaped to fit snuglyaround the forward ends of the walls thereof for retaining the lens tothe enclosure and to maintain the water tight seal required byUnderwriters Laboratories. Heretofore, typically screws are threadedthrough the lips of the trim cap and into the enclosure walls to retainthe lens across the forward opening of the enclosure.

It would be desirable to provide a channel letter assembly having a lensand trim cap which could be installed without incurring the laborintensive, and aesthetically displeasing, step of attaching the trim capwith screws. It would also be desirable to provide a less cumbersomemethod of disassembling the trim cap and lens to gain access to theinterior of the enclosure of a channel letter.

SUMMARY

Briefly, the present invention is embodied in a channel letter. For thepurposes of this description, a channel letter is defined as anilluminated contoured fixture in the shape of a letter of the alphabet,a numeral, an element of punctuation such as a comma, an exclamationpoint, or any other shape or form intended to constitute a portion of asign advertisement or display.

The channel letter of the present invention has a rear surface formounting against a raceway, a wall, or any other structure suitable forsupporting the signage. The walls defining the figuration of the letteror shape to be depicted are made of sheet metal, or plastic, having agiven thickness. A lighting element, such as a strip of LEDs accordingto the newly available technology or any other light source, ispositioned against, or proximal to, the rear surface of the enclosure toprovide illumination therefore.

A channel letter comprising an enclosure having at least two opposingwalls, wherein the at least two opposing walls defining the shape of theletter and having an open front; the at least two opposing walls havingan inner surface and a forward end; a lens having a forward surface andan outer edge in the shape of the letter; a plurality of selectivelypositioned and oriented retention clips adjacent the forward endfrictionally engaged with the enclosure walls; each clip includes anoutwardly extending leg relative to the walls; a retainer cap againstthe forward surface of the lens for retaining the lens adjacent theenclosure and the walls; the retainer cap comprises an extrusion readilyformable into a variety of shapes; the retainer cap includes an interiorface having a first edge and an opposing second edge; the first edgehaving an overhang engaged to the forward surface of the lens; and, thesecond edge having channel, wherein the channel adapted to securelyengage a plurality of the legs along an outer surface of the enclosurewalls.

A channel sign assembly comprising an enclosure having at least twoopposing walls, the at least two opposing walls defining the shape ofthe sign assembly and having an open front; the at least two opposingwalls having an inner surface and a forward end; the walls including aplurality of intermittent retention clips mounted adjacent to theforward end; each clip includes an outwardly extending leg relative tothe walls; the legs are aligned with and offset from the forward end; aplanar lens having a forward surface, and an outer edge in the definedshape of the sign and sized to fit within the at least two opposingwalls of the enclosure; a retainer cap against the forward surface ofthe lens for retaining the lens within the enclosure and against thewalls; the retainer cap comprises an extrusion readily formable into avariety of shapes; the retainer cap includes an interior face having afirst edge and an opposing second edge; the first edge having anoverhang engaged with the forward surface of the lens; and, the secondedge forming a retention channel, wherein the channel adapted tosecurely engage a plurality of the legs along an outer surface of theenclosure walls.

A channel sign assembly comprising an enclosure having at least twoopposing walls, the at least two opposing walls defining the shape ofthe sign assembly and having an open front; the at least two opposingwalls forming a forward end; the walls including a plurality ofintermittent retention clips mounted adjacent to the forward end; eachclip mounted in a first orientation includes a first outwardly extendingleg relative to the walls; the legs are aligned with and offset from theforward end; a planar lens having a forward surface and an outer edge inthe defined shape of the sign; a retainer cap mounted against theforward surface of the lens for retaining the lens within the enclosureand against the walls; the retainer cap comprises an extrusion readilyformable into a variety of shapes; the retainer cap includes an interiorface having a first edge and an opposing second edge; the first edgehaving an overhang engaged with the forward surface of the lens; and,the second edge forming a retention channel, wherein the channel adaptedto securely engage a plurality of the legs along an outer surface of theenclosure walls.

A channel sign assembly comprising an enclosure having at least twoopposing walls, the at least two opposing walls defining the shape ofthe sign assembly and having an open front; the at least two opposingwalls forming a forward end; the walls including a plurality ofintermittent retention clips mounted adjacent to the forward end; eachclip includes a unitary structure comprising a top edge, a planar body,and an outwardly extending leg relative to the body. The plurality ofclips and associated legs are aligned with and offset from the forwardend. The sign assembly further includes a planar lens having a forwardsurface and an outer edge in the defined shape of the sign. A retainercap can be mounted against the forward surface of the lens for retainingthe lens within the enclosure and against the walls. The clips furthercomprise double faced adhesive tape including a first face of the tapesecured to a mounting side of the body of the clip; a second face of thetape secured to an outer surface of the walls; and, the top edge of theclip including a first portion generally at about 90 degrees to the bodyfor resting on the forward end and stopping the clip at the propermounting position.

BRIEF DESCRIPTION OF THE DRAWINGS

A better and more complete understanding of the present invention willbe had after a reading of the following detailed description taken inconjunction with the drawings wherein:

FIG. 1 is an enlarged cross sectional view of channel letter walls,lens, and trim cap assembly shown with screws retaining the trim cap tothe walls of the enclosure as is known in the art;

FIG. 2 is an edge view of the retainer clip;

FIG. 3 is a front side view of the retainer clip;

FIG. 4 is a perspective view of the retainer clip;

FIG. 5 is an enlarged partial edge view of the retainer clip;

FIG. 6A is a cross sectional view of the channel letter assemblyemploying the retainer clip in accordance with the present invention anda first embodiment of trim cap;

FIG. 6B is a cross section view of the letter assembly employing theretainer clip in accordance with the present invention and a secondembodiment of trim cap;

FIG. 7 is a perspective view of a side wall of an enclosure with aretainer clip mounted thereon;

FIG. 8 is a perspective view of a side wall of an enclosure with theretainer clip mounted thereon along with the trim cap mounted theretoand the lens positioned thereabove.

FIG. 9 is an edge view of a retainer clip according to a secondembodiment;

FIG. 10 is a front side view of the retainer clip of FIG. 9;

FIG. 11 is a perspective view of the retainer clip of FIG. 9;

FIG. 12 is a cross sectional view of the channel letter assemblyemploying the retainer clip of FIG. 9 in accordance with the presentinvention;

FIG. 13 is an edge view of a retainer clip according to a thirdembodiment;

FIG. 14 is a front side view of the retainer clip of FIG. 13;

FIG. 15 is a perspective view of the retainer clip of FIG. 13;

FIG. 16 is a cross sectional view of the channel letter assemblyemploying the retainer clip of FIG. 13 in accordance with the presentinvention;

FIG. 17 is an edge view of a retainer clip according to a fourthembodiment;

FIG. 18 is a front side view of the retainer clip of FIG. 17;

FIG. 19 is a perspective view of the retainer clip of FIG. 17;

FIG. 20 is a cross sectional view of the channel letter assemblyemploying the retainer clip of FIG. 17 in accordance with the presentinvention; and,

FIG. 21 is a cross sectional view of a third embodiment of trim cap tobe employed with any of the retainer clips described in the presentdisclosure.

DETAILED DESCRIPTION

Referring to FIG. 1, a channel letter assembly 10 according to the priorart is mounted on a supporting structure 12. As shown, the channelletter assembly 10 includes a metal enclosure 14 having a rear surface16 and a plurality of side walls 18, 19 which are contoured to definethe edges of a letter 10. The forward edges of the sidewalls 18, 19define a plane and fitted across the forward edges is a transparent lens22 having a shape corresponding to that defined by the walls 18, 19 ofthe enclosure 14. Retained to the rear surface 16 of the enclosure 14 isa light source 23, which can extend through the length of the channelletter 10 thereby illuminating the entire surface of the lens 22.

In accordance with the prior art, the lens 22 is retained to the sidewalls 18, 19 of the enclosure 14 by a trim cap 24. The trim cap 24typically includes a plastic border member which can be glued, welded,or secured 25 to the outer edges of the lens 22. The trim cap 24 has arearwardly extending lip 26 that fits over the forward edges of the sidewalls 18, 19. The trim cap 24 and the lens 22 are retained to theenclosure member 14 by a plurality of screws 28. The screws 28 passthrough the trim cap's rearwardly extending lip 26 and screw into thesheet metal side walls 18, 19 of the enclosure 14.

The manufacture of a channel letter 10 in accordance with the prior artrequires the construction of the enclosure 14, the manufacture of lightfixtures 23 and the lens 22. Manufacture of the lens 22 requires cuttinga transparent acrylic or plastic material into the shape of the channelletter 10 and attaching the trim cap 24 around the edges thereof. Thetrim cap 24 is then secured to the edges of the lens 22 via screws 28.The trim cap 24 is intended to meet the present sealing standards set byUnderwriters Laboratories, but such standards may not be needed (or mayresult in different standards) for channel letters which employ the newLED technology. It would, therefore, be desirable to provide a lessexpensive and less cumbersome method of attaching a lens 22 to theenclosure of the channel letter 10. In addition, it would be desirableto provide a method that facilitates disassembly of the trim cap 24 andlens 22 from the enclosure for maintenance of the light fixture 23, andother components, within the enclosure.

Trim cap 24 can come in rolls and may be cut to any length. It canessentially be shaped to any configuration or size and is used to trimPlexiglas® letters or shapes (i.e. lens 22) by chemically welding thetrim cap 24 to the plastic shapes 22. The letters or shapes 22 can thenbe placed on a channel which can contain neon or LED lighting toilluminate the letters or shapes. The result is a three-dimensionalilluminated letter or shape. As discussed above, prior attachment meansfor securing the trim cap 24 to the outside of the metal channel 18, 19comprise holes drilled through the trim cap 24 and the metal channel 18,19 followed by screws 28 driven through the trim cap 24 into themetallic channel 18, 19 (i.e. for securing the trim cap thereto).

The use of screws is undesirable for a number of reasons. Screws are notaesthetically acceptable and they create depressions in the trim cap 24.Although not shown, the screws 28 peel when painted to match the trimcap 24 and can rust and freeze making it difficult to remove forservicing the sign assembly. The screws 28 cause staining (i.e. ruststreaks along the walls 18, 19) and often crack the trim cap 24. Thus,there is a need for an improved system for assembling trim cap lettersand numbers to a supporting channel.

Referring to FIGS. 2-8, and in accordance with the present disclosure, achannel letter assembly 100 having a retaining clip 32 is thereindisplayed. The clip 32 provides a means for securing a trim cap orretainer cap 34 to the walls 38, 39 of the enclosure 44. It is to beappreciated that trim cap 34 can include a metal insert 35 (i.e.aluminum) extending therethrough in order to provide rigidity andformability to the trim cap 34 shape. The metal insert 35 can bepositioned adjacent to an exterior side or imbedded within the interiorof trim cap 34. The insert 35 can extend through a portion of trim cap34 or through substantially the entire cross section of trim cap 34. Tofacilitate retention of a lens 42 against the front edges 58, 59 of thewalls 38, 39 of the enclosure 44, a plurality of the retainer clips 32are spaced along the front edges or terminal ends 58, 59 of the walls38, 39 of the enclosure 44. Each of the retainer clips 32 can comprise aunitary generally u-shaped rigid body 60 having a first side 62, asecond side 64, and an arched back 66 connecting the two sides 62, 64.Each of the sides 62, 64 includes a leg 63, 65 extending therefrom. Thelegs 63, 65 extend in a y-shape relative to each other and sides 62, 64.The legs 63, 65 form an enlarged receiving opening 70 for placement ofthe clip 32 onto the terminal ends 58, 59 of the side walls 38, 39 ofthe enclosure 44. The legs 63, 65 are spaced from each other at a firstend and form a first spaced distance 72 that is significantly greaterthan the given thickness of the sheet metal of the walls. The legs 63,65 taper towards each other at a second end to form a second spaceddistance 74 that is slightly greater than the thickness of the sheetmetal of the walls. A plurality of rigid barbs 80, 82, 84, 86 extendfrom the inner surface of the sides 62, 64, of the u-shaped body 60, andinto the space between the first side 62 and the second side 64. In oneembodiment, the barbs 80, 82, 84, 86 are crimped from the edges of bothsides of the body 60. The number and spacing of the barbs can vary. Inone arrangement, barbs 80, 82 are formed from a left edge and a rightedge of the first side 62; and, barbs 84, 86 are formed from a left edgeand a right edge of the second side 64. The body, legs, and barbs of theretainer clip 32 can be made from metal (i.e. stainless steel). Thebarbs 80, 82, 84, 86 can be arranged such that they are notperpendicular to the sides 62, 64 of the u-shaped body 60 from whichthey project, but are oriented at an angle with respect to theperpendicular with a component of the angle extending toward the archedback 66. The angled orientation of the barbs 80, 82, 84, 86 permit theclip 32 to be easily fitted over the terminal ends 58, 59 of the sidewalls 38, 39 of the enclosure 44 but resist removal of the retainer clip32 once it has been installed. A plurality of such retainer clips 32 canbe positioned around the outer edge of the walls thereby providing anattachment means for the trim cap 34 and lens 42 to the walls 38, 39 ofthe enclosure 44. Retaining the trim cap 34 to the walls 38, 39 of theenclosure in turn provides the means for securing the lens 42 to theenclosure walls 38, 39 thereby providing a water resistant cover to theinterior of the enclosure 44.

As best shown in FIGS. 2 and 5, the barbs 80, 82, 84, 86 may bepositioned on either or both of the sides 62, 64 and can extend at leasthalf the distance, or substantially half the distance 77, between thesides 62, 64. It should be appreciated that the walls of an enclosurefor a small channel letter can be made of a thinner gauge of metal thanthe walls of a larger channel letter, and therefore the spacing betweenthe legs of a retainer clip can be made to accept more than one gauge ofmetal. It should also be appreciated that the retainer clips 32 may bemanufactured in more than one size to provide desirable fitting betweenthe sides and clips in order to accommodate a variety of wallthicknesses (and materials), and a variety of trim cap sizes. It is tobe appreciated that the channel enclosure can be made from non-metalmaterials (i.e. rigid or semi-rigid plastics). Non-metal materials canbe used in conjunction with clips 32 discussed herein.

Referring to FIGS. 6A, 6B, and 7-9, the retainer clip 32 is fitted onthe forward end 58 of a wall 38 with the second or exterior leg 65extending outward away from the wall 38. The retaining clip 32 can beeasily installed because the barbs 80, 82, 84, 86 and sides 62, 64 willreadily flex as the sides 62, 64 are moved along the opposing surfacesof the wall 38 until the forward end 58 of the wall 38 is against thearched back 66 of the clip 32 as shown. When all the retainer clips 32have been installed along the walls 38, 39 of the enclosure 44 the lens42 can be positioned to rest on the outer surface of the arched backs 66of the clips 32. Referring to the figures, it is to be appreciated thatafter a retainer clip 32 has been installed, the angularly orientedbarbs 80, 82, 84, 86 will resist removal of the retainer clip 32. Thisis because friction between the surfaces of the wall 38, 39 and the freeend of the barbs 80, 82, 84, 86 will wedge the barbs between (and into)the surface of the wall 38, 39 and the associated side.

The retainer clip 32 is depicted as having two barbs 80, 82 extendingfrom opposing edges of one side 62 and two barbs 84, 86 extending fromopposing edges of the other side 64. It is to be appreciated that thebarbs 80, 82, 84, 86 could be arranged in any number of configurationson the opposing sides 62, 64 of the retaining clip.

In accordance with the present invention, to retain the lens against theterminal ends of the shoulder a plurality of retainer clips are spacedalong the outer end of the walls of the enclosure. Each of the retainerclips can comprise a unitary generally u-shaped rigid body having afirst side, a second side, and an arched back connecting the two sides.Each of the sides includes a leg extending therefrom. The legs extend ina y-shape relative to each other. The legs form an enlarged receivingopening for placement of the clip onto a terminal or forward end of aside wall of the enclosure. The legs are spaced from each other at afirst end and form a first spaced distance that is significantly greaterthan the given thickness of the sheet metal of the walls. The legs tapertowards each other at a second end to form a second spaced distance thatis slightly larger than the thickness of the side wall of the enclosure.A plurality of rigid barbs extends from the inner surface of the sidesof the u-shaped body and into the space between the sides. In oneembodiment, the barbs are crimped along edges of both sides of the body.The number and spacing of the barbs can vary. In one arrangement, barbsare formed from a left edge and a right edge of the first side; and,formed from a left edge and a right edge of the second side. The body,legs, and barbs of the retainer clip can be made from rigid metal (i.e.stainless steel). Also, the barbs are not perpendicular to the sides ofthe u-shaped body from which they project, but are at an angle withrespect to the perpendicular with a component of the angle extendingtoward the arched back. The angled orientation of the barbs permit theclip, using one-handed pressure, to be slid over the terminal or frontends of the side walls of the enclosure (in a first direction) butresist removal of the retainer clip once it has been installed (in asecond opposing direction). It is to be appreciated that the rigid barbs80, 82, 84, 86, can “bite” into relatively softer metal walls (i.e.aluminum) and non-metal walls as the clip 32 is slid over the ends ofthe walls 38, 39 of the enclosure 44 in the first direction. The“biting” of the barbs 80, 82, 84, 86 into the walls 38, 39, coupled withthe angled orientation of the barbs, resists removal of the clip 32 whenmoved in a second direction opposed to the first direction. To furthersecure the clips 32 to the enclosure walls 38, 39, a rivet or similar(not illustrated) can be installed through the aligned openings 67, 69in the sides 62, 64 of the clips 32 and through a corresponding wall 38,39. A plurality of such retainer clips can be positioned around thefront edge of the walls thereby providing an attachment means for thetrim cap to the walls of the enclosure. Retaining the trim cap (inplace) in turn provides the means for securing the lens to the enclosurewalls.

Referring to FIG. 6A, the channel sign assembly 100 in accordance withthe present disclosure, including a first embodiment of trim cap 34, istherein displayed. The assembly includes a metal enclosure 44 having aplurality of sheet metal side walls 38, 39. The retainer, snap cap, ortrim cap 34 can be attached, i.e. firmly glued to the lens 42. The lens42 and retainer cap 34 provide lateral support to the walls 38, 39. Thelens 42 and the retainer cap 34 prevent the walls 38, 39 from movingtowards each other and from bowing outward away from each other.

The clips 32, once installed, provide a tab or leg 65 that extendsoutward away from the walls 38, 39 of the channel and can engage a foot90 of the retainer cap (i.e. in a ‘snap cap’ or friction engagementarrangement). The foot 90 can extend in a length from about ¼ inch toabout 1¼ inches. The foot 90 of the retainer cap 34 can be in the formof a receiver or retention channel having a face 92 angled upward fromabout 3 degrees to about 9 degrees from horizontal. In one arrangement,the receiver can be angled upward from about 5 degrees to about 7degrees from horizontal.

The clips 32 can be placed onto the channel walls 38, 39 at randompositions around the letter or shape at the discretion of an installer.The number and intermittent spacing of the clips 32 will be dependentupon the size and design of the channel sign. The interlocking effect ofthe foot 90 of the retainer cap 34 to the tabs 65 will enable secureattachment of the plastic lens 42 and retainer cap 34 to the metallicchannel 38, 39.

The tabs 65 of the clips 32 can be positioned such that they are alignedwith and proximal to the front edge 58, 59 of the side walls 38, 39. Thefriction “locking” effect of the barbs enables a positive engagement ofthe inside faces of the clip 32 to the forward edge and forward sideportions of the metallic channel 38, 39.

FIG. 6B shows a cross-sectional view of the clip 32 as it would bealigned with the front edge of the side walls in conjunction with asecond embodiment of trim cap 134. Trim cap 134, or channel letterassembly 200, includes a slot 136 for receiving the edge 43 or lens 42.The slot 136 includes an upper leg 138, a lower leg 140, and a back edge142. The trim cap 134 further includes a foot 190 for engaging leg 65 ofclip 32. The foot 190 can be in the form of a receiver or retentionchannel having an angled face 192. The angled face 192 can be from above3 degrees to about 9 degrees from horizontal. The angled face 192 andfoot 190 provide a “snap fit” with leg 65 thereby securing trim cap 134to clip 32, wall 38, and lens 42.

FIGS. 7 and 8 show perspective views of the clip 32 as mounted to theside walls 38, 39.

In furtherance of the above described retainer cap 34, 134, a simplelever tool (i.e. two-pronged) angled lever can be used to facilitate thedetachment or removal of the plastic retainer or snap cap from the walls(i.e. metallic or non-metallic). The retainer cap 34, 134 can bedetached from the clips 32 using this separate tool which can bemanually lever driven. The lever tool can release the retainer cap 34,134 much as a bottle opener locks under a lid to pop the lid off using alever action.

When a channel sign assembly 100, 200 is assembled using the clips 32 asdescribed, the finished product will present a more attractiveappearance than one assembled using screws. In addition, when it is timeto service the sign assembly to replace LEDs, or other devices, thesnap/retainer cap 34, 134 can be pried off using the simple leverdevice. The lever device can reach between the retainer cap and the sidewall 38, 39 and then pull the receiver edge 92, 192 of the retainer cap34, 134 respectively, outward in order to free the edge 92, 192 from theterminal end of the outward side 65 of the clip 32. This prying processcan be continued for several clips 32 which will enable the servicetechnician to free the entire perimeter, or a desired portion thereof,of the retainer cap 34, 134 from the forward end 58, 59 of the channelsign enclosure 44 without the use of a screwdriver and the cumbersomeremoval of screws.

Referring to FIGS. 9-12, and in accordance with the present disclosure,a channel letter assembly 300 having a retaining clip 232 (according toa second embodiment) is therein displayed. The clip 232 provides a meansfor securing a trim cap or retainer cap 34 to the walls 38, 39 of theenclosure 44. To facilitate retention of a lens 42 against the frontedges 58, 59 of the walls 38, 39 of the enclosure, a plurality of theretainer clips 232 are spaced along the front edges or terminal ends 58,59 of the walls 38, 39 of the enclosure. Each of the retainer clips 232can comprise a unitary generally u-shaped rigid body 260 having a firstside 262, a second side 264, and an arched back 266 connecting the twosides 262, 264. Each of the sides 262, 264 includes a leg 263, 265extending therefrom. The first leg 263 extends linearly from side 262.The second legs 265 extends in a y-shape relative to the first side 262and leg 263. The legs 263, 265 form an enlarged receiving opening 270for placement of the clip 232 onto the terminal ends 58, 59 of the sidewalls 38, 39 of the enclosure 44. The legs, 263, 265 are spaced fromeach other at a first end and form a first spaced distance 272 that issignificantly greater than the given thickness of the sheet metal of thewalls. The leg 265 tapers toward leg 263 at a second end to form asecond spaced distance 274 that is slightly greater than the thicknessof the sheet metal of the walls. A plurality of rigid barbs 280, 282,284, 286 extend from the inner surface of the sides 262, 264, of theu-shaped body 260, and into the space between the first side 262 and thesecond side 264. In one embodiment, the barbs 280, 282, 284, 286 arecrimped from the edges of both sides of the body 260. The number andspacing of the barbs can vary. In one arrangement, barbs 280, 282 areformed from a left edge and a right edge of the first side 262; and,barbs 284, 286 are formed from a left edge and a right edge of thesecond side 264. The body, legs, and barbs of the retainer clip 232 canbe made from metal (i.e. stainless steel). The barbs 280, 282, 284, 286can be arranged such that they are not perpendicular to the sides 262,264 of the u-shaped body 260 from which they project, but are orientedat an angle with respect to the perpendicular with a component of theangle extending toward the arched back 266. The angled orientation ofthe barbs 280, 282, 284, 286 permit the clip 232 to be easily fittedover the terminal ends 58, 59 of the side walls 38, 39 of the enclosure44 but resist removal of the retainer clip 232 once it has beeninstalled. A plurality of such retainer clips 232 can be positionedaround the outer edge of the walls thereby providing an attachment meansfor the trim cap 34 and lens 42 to the walls 38, 39 of the enclosure 44.Retaining the trim cap 34 to the walls 38, 39 of the enclosure in turnprovides the means for securing the lens 42 to the enclosure walls 38,39 thereby providing a water resistant cover to the interior of theenclosure 44.

As best shown in FIG. 9, the barbs 280, 282, 284, 286 may be positionedon either or both of the sides 262, 264 and can extend at least half thedistance, or substantially half the distance, between the sides 262,264. It should be appreciated that the walls of an enclosure for a smallchannel letter can be made of a thinner gauge of metal than the walls ofa larger channel letter, and therefore the spacing between the legs of aretainer clip can be made to accept more than one gauge of metal. Itshould also be appreciated that the retainer clips 232 may bemanufactured in more than one size to provide desirable fitting betweenthe sides and clips in order to accommodate a variety of wallthicknesses (and materials), and a variety of trim cap sizes. It is tobe appreciated that the channel enclosure can be made from non-metalmaterials (i.e. rigid or semi-rigid plastics). Non-metal materials canbe used in conjunction with clips 232 discussed herein.

Referring to FIG. 12, the retainer clip 232 is fitted on the forward end58 of a wall 38 with the second or exterior leg 265 extending outwardaway from the wall 38. The retaining clip 232 can be easily installedbecause the barbs 280, 282, 284, 286 and sides 262, 264 will readilyflex as the sides 262, 264 are moved along the opposing surfaces of thewall 38 until the forward end 58 of the wall 38 is against the archedback 266 of the clip 232 as shown. When all the retainer clips 232 havebeen installed along the walls 38, 39 of the enclosure 44 the lens 42can be positioned to rest on the outer surface of the arched backs 266of the clips 232. Referring to the figures, it is to be appreciated thatafter a retainer clip 232 has been installed, the angularly orientedbarbs 280, 282, 284, 286 will resist removal of the retainer clip 232.This is because friction between the surfaces of the wall 38, 39 and thefree end of the barbs 280, 282, 284, 286 will wedge the barbs between(and into) the surface of the wall 38, 39 and the associated side.

To further secure the clips 232 to the enclosure walls 38, 39, a rivetor similar (not illustrated) can be installed through the alignedopenings 267, 269 in the sides 262, 264 of the clips 232 and through acorresponding wall 38, 39. A plurality of such retainer clips can bepositioned around the front edge of the walls thereby providing anattachment means for the trim cap to the walls of the enclosure.Retaining the trim cap (in place) in turn provides the means forsecuring the lens to the enclosure walls.

Referring to FIG. 12, the channel sign assembly 300 in accordance withthe present disclosure, including a first embodiment of trim cap 34, istherein displayed. The assembly includes a metal enclosure having aplurality of sheet metal side walls 38, 39. The retainer, snap cap, ortrim cap 34 can be attached, i.e. firmly glued to the lens 42. The lens42 and retainer cap 34 provide lateral support to the walls 38, 39. Thelens 42 and the retainer cap 34 prevent the walls 38, 39 from movingtowards each other and from bowing outward away from each other.

The clips 232, once installed, provide a tab or leg 265 that extendsoutward away from the walls 38, 39 of the channel and can engage a foot90 of the retainer cap (i.e. in a ‘snap cap’ or friction engagementarrangement). The foot 90 can extend in a length from about ¼ inch toabout 1¼ inches. The foot 90 of the retainer cap 34 can be in the formof a receiver or retention channel having a face 92 angled upward fromabout 3 degrees to about 9 degrees from horizontal. In one arrangement,the receiver can be angled upward from about 5 degrees to about 7degrees from horizontal.

The clips 232 can be placed onto the channel walls 38, 39 at randompositions around the letter or shape at the discretion of an installer.The number and intermittent spacing of the clips 232 will be dependentupon the size and design of the channel sign. The interlocking effect ofthe foot 90 of the retainer cap 34 to the tabs 265 will enable secureattachment of the plastic lens 42 and retainer cap 34 to the metallicchannel 38, 39.

The tabs 265 of the clips 232 can be positioned such that they arealigned with and proximal to the front edge 58, 59 of the side walls 38,39. The friction “locking” effect of the barbs enables a positiveengagement of the inside faces of the clip 232 to the forward edge andforward side portions of the metallic channel 38, 39.

Referring to FIGS. 13-16, and in accordance with the present disclosure,a channel letter assembly 400 having a retaining clip 332 (according toa third embodiment) is therein displayed. The clip 332 provides a meansfor securing a trim cap or retainer cap 34 to the walls 38, 39 of theenclosure 44. To facilitate retention of a lens 42 against the frontedges 58, 59 of the walls 38, 39 of the enclosure 44, a plurality of theretainer clips 332 are spaced along the front edges or terminal ends 58,59 of the walls 38, 39 of the enclosure 44. Each of the retainer clips332 can comprise a unitary structure comprising a top edge 363, a planarbody 364, and outwardly extending leg 365 relative to the body 364. Theclip 332 can be made from metal (i.e. stainless steel). A plurality ofsuch retainer clips 332 can be positioned around the outer edge of thewalls thereby providing an attachment means for the trim cap 34 and lens42 to the walls 38, 39 of the enclosure 44. Retaining the trim cap 34 tothe walls 38, 39 of the enclosure in turn provides the means forsecuring the lens 42 to the enclosure walls 38, 39 thereby providing awater resistant cover to the interior of the enclosure 44.

It is to be appreciated that the channel enclosure can be made fromnon-metal materials (i.e. rigid or semi-rigid plastics). Non-metalmaterials can be used in conjunction with clips 332 discussed herein.

Referring to FIG. 16, the retainer clip 332 is fitted on the forward end58 of a wall 38 with the leg 265 extending outward away from the wall38. The retaining clip 332 can be easily installed with a double facedadhesive tape 370 secured to the inside of the body 364. When all theretainer clips 332 have been installed along the walls 38, 39 of theenclosure 44 the lens 42 can be positioned to rest on the outer surfaceof the top edge 363 of the clips 332. Referring to the figures, it is tobe appreciated that after a retainer clip 332 has been installed, thetop edge 363 will ‘rest’ against the front edge 58 of the wall 58 andalong with the double faced adhesive tape 370 will resist removal of theretainer clip 332.

In accordance with the present invention, to retain the lens against theterminal ends of the shoulder a plurality of retainer clips 332 arespaced along the outer end of the walls of the enclosure. Each of theretainer clips 332 can comprise a unitary generally rigid body 364having a first interior side and a second exterior side. The top edge363, body 364, and leg 365 of the clip 332 can be made from rigid metal(i.e. stainless steel). Also, the top edge 363 can be at a generally 90degree angle relative to the body 364. The top edge 363 resting on thefront edge 58 of the wall 38, coupled with the double faced adhesive 370secured between the body 364 and wall 38, resists removal of the clip332. To further secure the clips 332 to the enclosure walls 38, 39, arivet 380 or similar (FIG. 16) can be installed through the opening 367in the body 364 of the clip 332 and through a corresponding wall 38, 39.A plurality of such retainer clips 332 can be positioned around thefront edge of the walls thereby providing an attachment means for thetrim cap to the walls of the enclosure. Retaining the trim cap (inplace) in turn provides the means for securing the lens to the enclosurewalls.

Referring to FIG. 16, the channel sign assembly 400 in accordance withthe present disclosure, including a first embodiment of trim cap 34, istherein displayed. The assembly includes a metal enclosure 44 having aplurality of sheet metal side walls 38, 39. The retainer, snap cap, ortrim cap 34 can be attached, i.e. firmly glued to the lens 42. The lens42 and retainer cap 34 provide lateral support to the walls 38, 39. Thelens 42 and the retainer cap 34 prevent the walls 38, 39 from movingtowards each other and from bowing outward away from each other.

The clips 332, once installed, provide a tab or leg 265 that extendsoutward away from the walls 38, 39 of the channel and can engage a foot90 of the retainer cap (i.e. in a ‘snap cap’ or friction engagementarrangement). The foot 90 can extend in a length from about ¼ inch toabout 1¼ inches. The foot 90 of the retainer cap 34 can be in the formof a receiver or retention channel having a face 92 angled upward fromabout 3 degrees to about 9 degrees from horizontal. In one arrangement,the receiver can be angled upward from about 5 degrees to about 7degrees from horizontal.

The clips 332 can be placed onto the channel walls 38, 39 at randompositions around the letter or shape at the discretion of an installer.The number and intermittent spacing of the clips 332 will be dependentupon the size and design of the channel sign. The interlocking effect ofthe foot 90 of the retainer cap 34 to the tabs 365 will enable secureattachment of the plastic lens 42 and retainer cap 34 to the metallicchannel 38, 39.

The tabs 65 of the clips 32 can be positioned such that they are alignedwith and proximal to the front edge 58 59 of the side walls 38, 39. Theadhesive securing the clips to the wall enables a positive engagement ofthe inside faces of the clips 32 to the forward edge and forward sideportions of the metallic channel 38, 39.

Referring to FIGS. 17-20, and in accordance with the present disclosure,a channel letter assembly 500 having a retaining clip 432 (according toa fourth embodiment) is therein displayed. The clip 432 provides a meansfor securing a trim cap or retainer cap 34 to the walls 38, 39 of theenclosure 44. To facilitate retention of a lens 42 against the frontedges 58, 59 of the walls 38, 39 of the enclosure 44, a plurality of theretainer clips 432 are spaced along the front edges or terminal ends 58,59 of the walls 38, 39 of the enclosure 44. Each of the retainer clips432 can comprise a unitary structure comprising a top edge 463, a planarbody 464, and outwardly extending leg 465 relative to the body 464. Theclip 432 can be made from metal (i.e. stainless steel). The top edge 463can comprise a fixed portion 473 and a spring tensioned portion 475. Inthe mounted position (FIG. 20), the spring tensioned portion 475provides on upward force to the lens 42 thereby increasing thesecurement force between leg 465 and foot 90. A plurality of suchretainer clips 432 can be positioned around the outer edge of the wallsthereby providing an attachment means for the trim cap 34 and lens 42 tothe walls 38, 39 of the enclosure 44. Retaining the trim cap 34 to thewalls 38, 39 of the enclosure in turn provides the means for securingthe lens 42 to the enclosure walls 38, 39 thereby providing a waterresistant cover to the interior of the enclosure 44.

Referring to FIG. 16, the retainer clip 432 is fitted on the forward end58 of a wall 38 with the leg 465 extending outward away from the wall38. The retaining clip 432 can be easily installed with a double facedadhesive tape 470 secured to the inside of the body 464. When all theretainer clips 432 have been installed along the walls 38, 39 of theenclosure 44 the lens 42 can be positioned to rest on the outer surfaceof the top edge 463 of the clips 432. Referring to the figures, it is tobe appreciated that after a retainer clip 432 has been installed, thetop edge 463 will ‘rest’ against the front edge 58 of the wall 38 andalong with the double faced adhesive tape 470 will resist removal of theretainer clip 432.

In accordance with the present invention, to retain the lens against theterminal ends of the shoulder a plurality of retainer clips 432 arespaced along the outer end of the walls of the enclosure. Each of theretainer clips 432 can comprise a unitary generally rigid body 464having a first interior side and a second exterior side. The top edge463, body 464, and leg 465 of the clip 432 can be made from rigid metal(i.e. stainless steel). Also, the top edge fixed portion 473 can be at agenerally 90 degree angle relative to the body 464. The top edge 463resting on the front edge of the wall, the biased spring portion 475coupled with the double faced adhesive 470 secured between the body 464and wall 8, resists removal of the clip 432. A plurality of suchretainer clips 432 can be positioned around the front edge of the wallsthereby providing an attachment means for the trim cap to the walls ofthe enclosure. Retaining the trim cap (in place) in turn provides themeans for securing the lens to the enclosure walls.

The tabs 465 of the clips 432 can be positioned such that they arealigned with and proximal to the front edge 58, 59 of the side walls 38,39. The adhesive 470 securing the clips 432 to the wall enables apositive engagement of the inside faces of the clips 432 to the forwardedge and forward side portions of the metallic channel 38, 39. Thespring biased portion 475 increases the securement tension between theclip 432 and the trim cap 34.

FIG. 21 shows a cross-sectional view of a third embodiment of trim capas could be employed with any of the retainer clips (not shown)described herein. Trim cap 534 can include a J-hook 536 for receiving(i.e. hooking) the edge 43 of lens 42. The J-hook 536 includes a curvedportion 538 and a terminal end portion 540. The trim cap 534 furtherincludes a foot 590 for engaging a leg of a clip (not shown). The foot590 can be in the form of a receiver or retention channel having anangled face 592. The angled face 592 can be from above 3 degrees toabout 45 degrees from horizontal. The angled face 592 and foot 590provide a “snap fit” with a retainer clip leg thereby securing trim cap534 to a clip, channel wall 38, and lens 42. Although not shown, it isto be appreciated that trim cap 534 can include a metal insert (i.e.aluminum) extending therethrough in order to provide rigidity andformability to the trim cap 534 shape. The metal insert can bepositioned adjacent to an exterior side or imbedded within the interiorof trim cap 534. The insert can extend through a portion of trim cap 534or through substantially the entire cross section of trim cap 534.

While embodiments of the present disclosure have been disclosed, it willbe appreciated that many modifications or variations may be made withoutdeparting from the true spirit and scope of the disclosure. It is,therefore, the intent of the pending claims to cover all such variationsand modifications which fall within the true spirit and scope of thedisclosure.

What is claimed:
 1. A channel sign assembly comprising: an enclosurehaving at least two opposing walls, said at least two opposing wallsdefining the shape of said sign assembly and having an open front; saidat least two opposing walls having an inner surface and a forward end;said walls including a plurality of intermittent retention clips mountedadjacent to said forward end; each said clip includes a unitarystructure comprising a top edge, a planar body, and an outwardlyextending leg relative to said body; said legs are aligned with andoffset from said forward end when each said clip is in a mountedposition; a planar lens having a forward surface, and an outer edge insaid defined shape of said sign and sized to fit within said at leasttwo opposing walls of said enclosure; a retainer cap against saidforward surface of said lens for retaining said lens within saidenclosure and against said walls; said retainer cap comprises anextrusion readily formable into a variety of shapes; said retainer capincludes an interior face having a first edge and an opposing secondedge; said first edge having an overhang engaged with said forwardsurface of said lens; and, said second edge forming a retention channel,wherein said channel adapted to securely engage a plurality of said legsalong an outer surface of said enclosure walls.
 2. A channel designpattern in accordance with claim 1, wherein each said clip comprisesdouble faced adhesive tape including a first face of said tape securedto a mounting side of said body of said clip; a second face of said tapesecured to an outer surface of said walls; and, said top edge generallyat about 90 degrees to said body for resting on said forward end andstopping said clip at the proper mounting position.
 3. A channel designpattern in accordance with claim 1, wherein said top edge includes aspring biased portion.
 4. A channel sign assembly comprising: anenclosure having at least two opposing walls, said at least two opposingwalls defining the shape of said sign assembly and having an open front;said at least two opposing walls forming a forward end; said wallsincluding a plurality of intermittent retention clips mounted adjacentto said forward end; each said clip includes a unitary structurecomprising a top edge, a planar body, and an outwardly extending legrelative to said body; said legs are aligned with and offset from saidforward end; a planar lens having a forward surface and an outer edge insaid defined shape of said sign; and, a retainer cap mounted againstsaid forward surface of said lens for retaining said lens within saidenclosure and against said walls.
 5. A channel sign assembly inaccordance with claim 4, wherein said retainer cap comprises anextrusion readily formable into a variety of shapes; said retainer capincludes an interior face having a first edge and an opposing secondedge; said first edge having an overhang engaged with said forwardsurface of said lens; and, said second edge forming a retention channel,wherein said channel adapted to securely engage a plurality of said legsalong an outer surface of said enclosure walls.
 6. A channel signassembly in accordance with claim 5, wherein said channel of said secondedge includes a receiver adapted to receive said plurality of said legs,wherein said receiver is positioned at an angle from about 3 degrees toabout 9 degrees from a horizontal plane wherein said horizontal plane issubstantially perpendicular to said enclosure walls.
 7. A channel signassembly in accordance with claim 6, wherein said receiver includespartially flexible material extending inwardly from said interior faceof said retainer cap, wherein said legs wedge between said retentionchannel and said exterior face of said enclosure walls when saidretainer cap is fitted against said enclosure walls.
 8. A channel signassembly pattern in accordance with claim 4, wherein each said clipcomprises double faced adhesive tape including a first face of said tapesecured to a mounting side of said body of said clip; a second face ofsaid tape secured to an outer surface of said walls; and, said top edgeincluding a first portion generally at about 90 degrees to said body forresting on said forward end and stopping said clip at the propermounting position.
 9. A channel sign assemble pattern in accordance withclaim 4, wherein said top edge includes a spring biased portion.
 10. Achannel sign assemble pattern in accordance with claim 8, wherein saidtop edge includes a second spring biased portion.
 11. A channel signassembly in accordance with claim 5, wherein said channel of said secondedge includes a receiver adapted to receive said plurality of said legs,wherein said receiver includes partially flexible material extendinginwardly from said interior face of said retainer cap.
 12. A channeldesign pattern comprising: an enclosure having at least two opposingwalls; said at least two opposing walls having an inner surface and aforward end; a plurality of selectively positioned and orientedretention clips adjacent said forward end; each said clip includes atleast one outwardly extending leg relative to an outer surface of saidwall; a retainer cap against said forward surface of said lens forretaining said lens adjacent said enclosure and said walls; saidretainer cap includes an interior face having a first edge and anopposing second edge; said first edge having an overhang engaged to saidforward surface of said lens; and, said second edge having channel,wherein said channel adapted to securely engage a plurality of said legsalong an outer surface of said enclosure walls.